The funding in three Halter LoadAssistant robotic programs by German subcontractor Euler Feinmechanik to assist its DMG Mori lathes has boosted productiveness, lowered prices and enhanced competitiveness. PES experiences.
German subcontractor Euler Feinmechanik, primarily based in Schöffengrund, north of Frankfurt, has invested in three robotic machine tending programs from Dutch automation specialist Halter to automate loading and unloading on a variety of DMG Mori lathes. The Halter sequence of LoadAssistant robotic machine tending tools is on the market within the UK by way of Salisbury-based 1st Machine Software Equipment.
Established greater than 60 years in the past and with round 75 workers, Euler Feinmechanik machines complicated turned and milled elements comparable to optical bearing mounts, elements for digital camera lenses, rifle scopes for searching and the navy, medical and aerospace elements, and housings and stators for vacuum pumps. Supplies machined are primarily aluminium, brass, stainless-steel and numerous plastics together with PEEK, acetal and PTFE.
Managing director Leonard Euler feedback: “Our manufacturing processes embrace milling, however are centred primarily on CNC turning of prototypes, pre-production batches and sequence elements.
“We develop product-specific manufacturing methods for our clients, for instance Airbus, Leica and Zeiss, and assist them from the event and manufacturing levels by way of to floor ending and meeting. Automation and robotisation are vital facets of our steady enchancment. We’re consistently fascinated about whether or not we will optimise particular person processes in order that they interface much more easily.”
In 2016, Euler Feinmechanik purchased a brand new CTX beta 800 4A CNC turn-mill centre from DMG Mori for the manufacturing of notably complicated elements for vacuum tools. The corporate knew on the time that it wished to automate the machine, however first needed to set up a dependable course of to supply the workpieces to the required top quality.
That was the accountability of Marco Kühnl, senior technician and the turning division’s crew chief.
He says: “In view of the growing order portions for the elements, we bought our first loading robotic in 2017. It has allowed us to extend productiveness from the brand new DMG Mori lathe whereas getting labour prices below management.”
A number of manufacturers of machine tending tools had been thought of, as Mr Euler was eager to search out the perfect answer and make a future-proof alternative on which the subcontractor may standardise.
He explains: “DMG Mori itself was additionally within the operating, because it had simply launched its personal Robo2Go robotic. This appeared to us to be essentially the most logical mixture and it’s certainly a pleasant product, however it may solely be programmed when the lathe shouldn’t be operating.
“Nonetheless, Halter is a specialist on this area and never solely had an excellent automation answer, but in addition nice references and a working demonstration that confirmed precisely what we wished. In the long run, we opted for one in all its Common Premium 20 cells.”
There have been numerous causes for the choice, one in all which was the usage of high-quality elements within the development, comparable to a FANUC robotic, Schunk grippers and a laser security system from Sick. Moreover, the robotic cell is manufactured in Halter’s manufacturing facility in Germany, the place the software program can be developed.
Because the producer makes use of its personal working system, programming the cell whereas the robotic is operating is easy. As well as, whereas the robotic is loading the machine on the entrance of the cell, an operator is ready to insert uncooked materials into the system from the rear and take away machined elements. With the ability to do all this concurrently avoids having to cease the turning centre and lose manufacturing.
Furthermore, the cell Common Premium 20 will be moved rapidly from one machine software to service one other, offering a excessive diploma of manufacturing versatility on the shopfloor.
The cell is designed for computerized loading of billets and unloading of machined workpieces to a most diameter of 270mm. A buyer can select from a big choice of grid plates of various capacities for buffer storage, which accommodate rectangular in addition to spherical workpieces and tall elements.
To facilitate connection of the loading robotic to the CTX beta 800 4A, Halter geared up the machine with an automation interface. This service is a giant benefit in contrast that offered by opponents. Halter is ready to interface with any model of CNC machine, no matter its sort and 12 months of manufacture.
The DMG Mori lathe is primarily used for machining elements from 130mm to 150mm diameter. Owing to its twin-spindle configuration, two workpieces will be produced in parallel. After automating the machine with the Halter cell, productiveness elevated by about 25%.
A 12 months after buying the primary DMG Mori turning centre and retrofitting it with automated loading and unloading, Euler Feinmechanik purchased two extra lathes from the identical supply. One is one other CTX beta 800 4A, whereas the second is a smaller CLX 350 dedicated to producing about 40 totally different elements for the optical business.
The 2 new machines had been instantly geared up with Business 4.0-compliant Halter loading robots similar to the primary. Manufacturing on all three twin-spindle lathes can proceed unattended for a median of half a shift, which maximises productiveness and reduces labour prices.
Automation has improved manufacturing effectivity to such an extent that the subcontractor intends to proceed automating its plant. A Halter LoadAssistant is deliberate for an current DMG Mori lathe on the shopfloor and asking Halter so as to add further features like workpiece sharpening and grinding to the automation cells is being thought of.
Assured of the longer term, Mr Euler concludes: “Automation has improved the utilisation of our CNC machines, elevated output and high quality, and decreased our hourly charges. The decrease price of manufacturing plus even quicker, extra dependable supply has strengthened our competitiveness.
“With out unscheduled machine downtime we will plan manufacturing higher and are not so reliant on workers being current, so we will extra simply deal with holidays and absences as a consequence of sickness.
“Automation additionally makes jobs extra engaging, so it’s simpler to search out workers. Youthful workers specifically present nice curiosity in and dedication to the expertise.”
1st Machine Software Equipment